Electrical machine



y 14, 1929- E. B. PHILLIPS 1,713,089

ELECTRICAL MACHINE Filed Jan. 3, 1927 2 Sheets-Sheet l INVENTOR May 14, 1929. E. B. PHILLIPS ELECTRICAL MACHINE Filed Jan. 3, 1927 2 Sheets-Sheet NVENTOR E Byla h 'qlwo.

Patented May 14, 1929 i UNITED STATES EMORY B. PHILLIPS, OF PITTSBURGH, PENNSYLVANIA.

. ELECTRICAL MACHINE.

Application f led. January 3, 1927. Serial No. 158,544.

This invention relates. to electrical machines, and particularly to commutating means therefor. t is equally applicable to motors, generators and converters.

Commutators heretofore constructed have comprised copper segments separated from one another by thin sheets of mica. The peripheral surface of the commutators has generally comprised a true cylindrical surface, although in a few cases the mica has been terminated at short distance below the peripheral surface.

It has been considered essential in high voltage machines to employ armatures of rel atively large diameter in order to overcome the dilliculties inherent to commutators of the present type. \Vith a large di meter machine more coils and corresponding segments may be employed, thus reducing the diii'erence in voltage between adjacent segments.

The difliculty with large diameter machines is that they are relatively heavier per unit of 'apacity than small diameter machines are more expensive to'build, and require a considerably larger amount of copper in the end portions of the coils, which portions have no function except to connect the active portions of the coils, and simply constitute a necessary expense in construction.

In addition to the above difficulties, a large diameter machine requires a greater core depth in the armature in order to properly carry the magnetic flux over the relatively greater distance between the field poles.

During commutation a brush spanning adjacent segments is functioning to temporarily short circuit the coil over the period during which the segments on the particular coil are in contact with the brush and cause a reversal of the direction in which current flows in the coil. This is true whether the machine is a motor in which current is supplied to the coil, or in the case of a generator in which current 's generated in the coil.

t is desirable that the value of the current through the coil over the period of conmutzn tic-n shall change in substantially straight line relation with time during the period of con'miutation from maximum coil current flowing in one direction to maximum coil current flowing in the other direction. The self-induction of the coil itself tends to defeat this object, and commutating poles and compensating windings have been employed to remedy the situation. Connnutating poles,

howerer, are limited in their effectiveness be cause of the fact that their cores become magnet ically saturated and the effect of the commutating pole is strictly imited by this factor. lVhile t'tllllpfilltitltlllg windings may be somewhat helpful in partially preventing such core saturation, they are not a cure for the condition.

During commutation a. voltage difference is set up between the segments of a coil which is being commutat-ed. This voltage dil'lerence represents the diiiercnce in magnitude of the rcactance voltage in the coil and the voltage induced by the eommutating pole flux. This last is commonly known as the con'lmutating voltage. There is a flow of current from one segment through the brush and thence to the other segment due to this unbalanced voltage. This current How is principally limited by the contact resistance between the brush and the segments. As a segment passes out from under the brush the area of contact between the brush and that particular segment becomes less and less, and the'contact resistance between the brush and this particular segment therefore increases.

As the adj .ccnt segment comes into engagement witii the brush, the area of contact between the brush and such segment increases between the brush and this particular segment. It is this continuous change in area of contact as the segments move over the brush which gives a choke effect and causes the proper division of flow of the main armature current through the segments in contact with the brush, and if no other mitigating causes are present, causes the current change in the coil to be at a uniform rate.

Brushes are generally made of carbon because of its desirable electrical properties. The value of the contact resistance is limited and this brings us back to the original statement that the voltage difference between the reactance voltage and the commutating voltin the coil being eommutated must be held to a low figure if heating and flashing are to be avoided.

I provide at least three brushes connected in series and forming a part of the electrical path for the short circuit current of the armature coil, thus nat ally increasing the contact resistance. I employ a commutator whose segments are connected to the armature coils, and asecond commutator whose segments are insulated from the first comincreased radiation. surface.

mutator and whose segments are not connected to the armature coils.

Brush members are employed in connection with both con'nnutators. These brush members are so arranged and connected that the short circuit current passes from a segment in the first commutator through a brush connection to a segment of the second commutator, thence through another brush member to another segmentof the second eonnnutator, and thence through a brush connection to a segment of the first commutator, completing the path for the short circuit current.

In order to prevent current from passing directly from a segment of the first commutator through the cooperating brush to a second segment of the same commutator, I make the brush in several portions insulated from one another. The segments are cut away in part so that the peripheral contacting surface of each segment is narrower than the segment proper. The space between the contacting surfaces of adjacent segments is made greater than the width of the brush portions.

This commutator arrangement is of value because it permits ofbcttcr insulation between segments, as will be hereinafter pointed out. It also is effective for breaking up the ionized layer of gases which is set up on commutators of the ordinary type. The presence of the layer of ionized gases on the peripheral surface of a commutator is responsible to a large degree for flashing trouble, and this is eliminated with my construction.

A commutator of this character will. not heat up as rapidly as a commutator of the ordinary type, because cooling is assisted by the windage effect occasioned by the interrupted periphery, and also by the materially This construction also permits of terminating the mica between segments at a distance below the peripheral surface greater than the total per missiblc wear on the commutator, thus doing away with all high mica troubles.

With my construction a much better choke effect at the commutator is obtained. A higher reactance voltage in the coils and a correspondingly higher commutating voltage is permissible. It is therefore possible to use armature coils having a longer active portion. I am thus enabled to make high voltage machines with smaller diameter and longer armatures, with a material saving in copper and other materials. as well as improving the eflieiency of the machine.

In the accompanying drawings which illustrate more or less diagrammatically the present preferred embodiment of my invention and certain modifications thereof.

Figure 1 is a perspective view of a portion of a commutator.

Figure 2 is a perspective View of a brush member adapted to cooperate with the commutator of Figure 1,

F igure 3 is a perspective view showing the arrangementof two commntators with the several brushes in engagement therewith,

Figure 4 is a diagran'nnatie view illustrating a modification wherein additional brushes are employed in series,

Figure 5 is a diagrammatic view showing my invention applied to connnutators wherein brushes are employed in parallel,

Figure 6 is a perspective view of a modified commutator construction,

Figure 7 is a section taken on the line VII-VII of Figure 6,

Figure 8 is a section taken on the line VIII-VIII of Figure 6,

Figure 9 is a section taken on the line IX-IX of Figure 6, and

Figure 10 is a diagrammatic view showing the arrangement of brushes with the commutator of Figure 6.

Referring first to Figures 1 to 3 inclusive, there is shown a commutator made of segments 2 separated by mica insulators 3. The outer face of each segment is cut away so as to leave a relatively narrow brush contacting surface 4 and recessed portions 5.

The insulating portions 3 are terminated a distance below the brush contacting surface 4, as indicated at 6. The distance (I is made greater than the permissible wear on the con'nnutator. It will be noted from Figure 1 that the insulating portions project above the recessed portions 5 as this materially improves the insulation between segments. All parts of the commutators except the brush contacting surface sl are covered with a suitable non-conductir g enamel. Two commutators of the type illustrated in Figure 1 are employed. One of them, termed the primary connn'utator, is ind -ated at P in Figure 3, and the second one, termed the secondary comn'iutator, is indicated at S in the same drawing.

The brush is made of portions 7 separated by mica insulating plates 8. The insulating plates 8 project a slight distance beyond the sides and top surfaces of the brush members 7, as shown in Figure 2. The edges of the insulating plat-es adjacmit the contact surface 9 are not made parallel to the line of contact of the brush with the commutator, but at an angle thereto, as in dicated at 10 in Figure 3. This arrangement insures av better air draft and thus prevents the accumulation of carbon dust or the like between adjacent brush portions 7. The insulating plates 8 are terminated at short distance c from the contacting surface 9, which distance is greater than the total permissible wear on the brush.

The brush portions 7 are held in a brush frame 11 by rivets or screws 12. The brush portions 7 are insulated from the brush frame 11 and the screws 12. Each brush portion 7 is provided with a conductor 13. The brush assembled brush in place. The tact that the brush frame is insulated from the brush members materially simplii'ies the construction, as it does away with any necessity for specially insulating the brush lJOX, or constructing it of non-insulating materials. On the contrary, the brush box may be made of metal with the assurance that the brush will fit closely in the box and at the same time always be slidable therein.

It will be noted from Figure that the brush portions 7 are of such width that any one brush portion can never be in contact .with two commutator segments at the same time.

The direction of rotation of the armature is indicated by an arrow 1* in Figure 3. An armature coil G will be considered to show the operation.

The coil C is provided with leads 1 1 and 15 terminating in segments 2 and 2", respectively, of the primary commutator P. At the time that substantially the entire -ontacting surface 4t of the segment 2 lies under the brush member 7 the leading edge L 01 the segment 2 comes into contact with the brush member 7 The path of the short circuit current is from the coil C through the lead 1 1, to the segment 2 and thence to the brush member 7 R A conductor 13 leads the current from the brush member 7 a to a corresponding brush member 7, cooperating with the secondary commutator S. The secondary commutator has a segment j so arranged that it engages and leaves the brush 7 c at the same time that segment 2 engages and leaves the brush 7. The short circuit current flows througn the brush 7 to the segment 2 and then length wise of the segment to a brush member 16. This brush member spans several segments of the secondary commutator and. is provided with a conductor 17 through which the main armature current flows. The short circuit current is enabled to reach a segment 2 through the brush member 16. The segment 2 is arranged to engage and leave a brush member 7 at the same instant that the segment- 2" engages and leaves the brush member 7 The brush members 7" and 7 are connected by a conductor 13". The short circuit current thus flows from the segment 2 through the brush 16 to the segment 2, thence through the brush member 7 the conductor 13 the brush member 7 and the segment 2" to the lead 15.

As above stated, the value of the contact resistance is relatively small and cannot be increased in ordinary construction. t will be seen, however, that with my construction there is a contact resistance between the segment 2* and the brush portion 7 another contact resistance between the brush portion 7 and the segment 2; another between the segment 2 and the brush 16; another between the brush 16 and the segment 2; another between the segment 2 and the brush portion 7 and another between the brush portion 7 and the segment 2". Instead of having two contact resistances, as is the case in the ordinary commutator, there are six contact resistances, and since these are in series the re sistance to current flow through the brush system from the segment 2 to the segment 2 is increased threefold. This permits of a material increase in the reactance voltage and the con'nnutating voltage, despite the fact that as the value of these two increases, there is a greater voltage difference between segments. The shape of: the segments themselves prevents the c irrent jumping over the insulation between segments.

Figure 1 shows a construction wherein a larger number of brushes is employed. The primary and secondary commutators arc indicated at P and S The operation of this form of the invention will be shown in connection with the commu tation of a coil whose leads are indicated at 17 anl 18. The lead 17 terminates in a segment 2, and the lead 18 terminates in a segment 2. During commutation the short circnit current flows from the segment 2 to a brush member 7, thence through a conductor 13 to a brush member 7- on the secondary commutator S Current flows from the brush member 7 to a segment on the secondary commutator and thence to a brush member 7.

From the brush member 7 the short circuit flows through a conductor 19 to a brush member 20 engagi g a segment 21 on the secondary commuta or. A brush spans the segment :21 and an adjacent segment 23. The main arn'iature current flows through a conductor 2% connected to the brush The short circuit current flows from the br sh 22 to the segment 22; and thence to a. segment 20" from a part oi the same brush construction as does the segment- 20. The short circuit current travels from the brush 20 through a conductor 19" to a brush member 7 thence through a segment 2 on the condary conimutator to a brush member 7. From the brush member 7 it flows through a conductor 13 to brush member 7 and thence through the segment 2 of the primary con'nnutator to the lead 18.

. The several brushes are so arranged that the brush portions 7 7 7 and 20 make contact at substantially the same instant with corresponding ctumnutator segments. The parts are also so arranged that brush members 7 7*, 7 20" and 22 mal-te substantially simultaneous contact with corresponding segments.

It was pointed out in connect-ion with the apparatus of Figure 8 that the resistance to flow of the short circuit current might be increased to three times the value obtainable with ordinary commutators. It will be seen that with the above des-acribed arrangement of Figure l, the resistance to How of the short circuit current can be increased to .tive times the ordinary figure.

Figure 5 shows a structure operating" on the same principle as the apparatus at Figure 3, but the brushes are in a series-parallel arrangement as is done in high currentcapacity machines. On the primary comnmtator P I provide two composite brt 1 structures 7 and 7 whose correspondi brush portions are connected by conductors 25. These conductors lead to composite brush members 26 and 27 on the secondary commutator S. Brush members 16 and 16 are located alongside the composite brush members 26 and 27. The main armature current flows through a conductor 28. The brushes 7, 7 26, 16 :27 and 16 are all so arranged that they are engaged by connnutator segments at substantially tl e same instant.

Figures (5 to 10 inclusive illustrate another forniot the invention which is particularly useful if the current capacity is such that an unduly long commutator is not required. In this form of the inventionthe segn'ients of the primary connnutator P, and of the see ondary con'nnutator are staggered one with respect to the other. Instead of recessing the commutator segments, as is done in the e1nbodiments of the invention heretofore described, the segments of each con'm'uitator are made only of the width desired for the brush contacting surface and the necessary spacing is secured by extending the segments of one commutator substantially the length ol the other commutator. This is clearly shown in Figure 6, where a segment 30 of the primary commutator has a port-ion 31 of full height to make contact with the brushes, and a portion 32 of reduced height which extends between the segments of the secondary con'mn'itator 8,. Similarly each segment of the secondary commutator S, has a portion 33 of full. height so as to make contact with the brushes, and a portion of reduced height which extends between the portions 31 of the primary commutator 1 Mica strips extend the full length of both commutator-s so as to provide the necessary insulation. Vith this construc tion the entire commutator assembly may be clamped with only two V rinq s, whereas in the en'ibodiments of Figures 1 to 5 inclusive, both the primary and secondary comn'iutators require two V rings.

The relative size and position of the several parts in the conmmtator of Figure 6 is best shown in Figures 7 to t) inclusive.

Figure 10 illustrates diagrainmatically the arrangement of brushes with the commutator of Figure 6. A composite brush 36 makes contact with the prunary comnnitator P and a corresponding brush 37 is employed in con-.

cl that it is not limited to this form alone, it may be otherwise embodied within the st pe of the following claims.

I claim 1. In an electrical machine, a commutator, a c il and at least three brushes connected in series and forming apart of the electrical path for the short circuit current of said coil, the series connection being at least in part through the commutator.

2. In an electrical machine, a commutator, a coil and at least three brushes connected series and forming a part of the electrical path for the short circuit current of said coil, the series connection being at least in part through the commutator, there being an odd niunber of brushes.

3. In an electrical machine, an armature coil, :1 commutator having a segment connected to the armature coiha brush cooperat- "th the commutator, a second commutaand a brush for the second commutator ected to the first brush, the commutators and brushes and their connection forming a part ot the electrical path for the short circuit current of the armature coil.

1. In an electrical machine, an armature coil, a. commutator having a segment connected to the armature coil, a brush cooperating vith the commutator, a second commut tor. a brush for the second commutator connet-ted to the first brush and means including a conductor for the main armature current fo connecting the armature coil to said condi'ctor through said commutators and brushes in series.

In an electrical machine, a coil and a plurality of eomniutators having brushes, the ezuumutators and brushes being arranged in series relation in the path through which the 1r :t circuit current of the coil flows.

In an electrical machine, a commutator having segments, a plurality of primary brush portions for the con'unutator engaging differ-en t segu'ients thereof, a second commutator, a plurality of secondary brush portions tor the second commutator engaging different segments thereof, connections between the modifications thereof, but it will be under-.

as to make contact with corresponding segbrush portions of the two commutators and a brushmemher connecting those segments of the second commutator which are engaged by the secondary brush portions.

7. In an electrical machine, a commutator having segments, a plurality of prii'nary brush portions for the commutator engagi diiierent segments thereof, a second commutator, a plurality oi secondary brush 130' ms for the second commutator engaging ditlen ent segments thereof, connections he ween the brush portions of the two commm' ators and a brush member connecting those segments of the second commutator wl ich are by the secondary brush portions, th 1 prinr and secondary brush portions being so r lated ments on the first and second commutators substantially the same instant.

8. In an electrical machine, a comn'iutator having segments, a plurality of primary bru 1 portions for thecommutator engaging i lierent segments thereof, a second co tor, a ilurality oi secondary hru for the second comn'iutator en segments thereof, connections i brush portions oi? the two commutator-s and a brush member connecting those segments of the second commutator which are eng nd by the secondary brush portions, the prin'iarv and secondary brush portions and the bra a member being so related to make substantially simultaneous contact with orresponding segments on their respective commutators.

9. In an electrical machine, a coil and plurality of commutators having brushes the commutators and brushes being arrat in series relation with the coil, the brushes tor the several commutators being so rela ted as to make contact with corresponding segments on their respective commutator-s substantially the same instant.

10. In an electrical machine, an arn'iature having coils, a commutator connected to the coils, a second commutator isolated from the coils, brush connections adapted to connect segments of the first commutator with segmentsof the second commutator and brush means for connecting such segments of the second commutator.

' 11. In an electrical machine, an armature having coils, a. commutator connected to tie coils, a plurality of brush means arranged nose 5 to substantially simultaneously engage the same segments of the commutator, a second commutator isolated from the coils, a plurality oi? lorush members connected to the first nentionet brush members and adapted to cp -e therewith connect segments of st commutator with segments of the ommutator, and brush means for con- In an electrical machine, an armature a commutator connected to the ality or brushes adapted to sul unultaneously engage the same commutator, each brush memoi? a plurality of brush porin one another and adapted "l'erent segments of the commucommutator isolated from the tater. lo. eccrieai machine, an armature h ving coils, commutator connected to the coils, a hrush portion adapted to make contact with a segmen the commutator, a second commutator isolated from the coils, a plusecond comn u in a ran 1 of brush por ions adapted to engage V .l I A \J 0 di 1 nents of the second comn'iutator a no t a segment of the first coinsuch scgi'nents of the second 4 tor, a. second brush portion for the h tor adapted to engage a differ- .7 r nt segment thereof, a plurality of brush connected to the second brush pori? the t commutator and adapted "o en age segments oi? the second commutator from those engaged by those brush no, tions which are connected to the first menl ish portion oi the first commutator, adapter to connect segments .nd commutator so as to form an Q A path from one oi the brush porthe mentioned commutator i'ihrou *h the brush portions 01: the second comtorbacl; to the second mentioned brush ion tor the first commutator. In testimony whereof I have hereunto set my hand.

EMORY B. PHILLIPS. 

